Rearview mirror constructed for efficient assembly

ABSTRACT

A mirror assembly includes a housing, an angularly adjustable power pack, wires for supplying power and mirror angle control, an electrochromic mirror subassembly including a heater, and a turn signal device. The components include individual connectors that plug into a multi-prong connector on the bundle of wires, or that piggyback into each other. Optionally, the heater incorporates an internal wire with end connectors for communicating power to opposite sides of the heater, and also includes layers of light-transmitting/diffusing material for diffusing light passing from the turn signal device through the diffusing material. A printed circuit board fits into a pocket in the panel-shaped carrier, and an integral retainer releasably secures the printed circuit board. The power pack is attached to the carrier via a ring of resilient fingers, and a continuous hoop flange prevents distortion of the carrier and in turn of the glass elements in the mirror subassembly.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation of U.S. patent applicationSer. No. 09/862,414, filed on May 21, 2001 by Bradley L. Busscher et al.the entire disclosures of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to a rearview mirror for vehiclesconstructed for efficient and optimal assembly, including componentsshaped for efficient and low-scrap molding and manufacture, componentshaving features integrated into them to reduce the overall number ofparts, pieces, and total weight, and components arranged to facilitatemechanical assembly and physical layout as well as electricalinterconnection and repair of electrical circuits.

[0003] Modern vehicle mirrors often include numerous electricalcomponents that must be powered and also controlled. For example, theelectrical components of one proposed high-end exterior mirror willinclude an electrochromic image-darkening mirror subassembly and controlcircuit, a heater, a turn signal, and a powered angular adjustmentmechanism. Other mirrors, such as interior mirrors, include a multitudeof sensors, buttons, and readouts/displays. Routing of wires to supportthe various electrical components can be a logistic nightmare, andfurther, even if routed carefully and consistently, can take upconsiderable space. Also, most mirror designs provide electricalconnectors so that the mirror can be electrically coupled to a vehicle'selectrical system on or about the same time as the mirror ismechanically attached to the vehicle. It is desirable to reduce theamount of time that it takes to arrange wiring and connectors on themirror, and to reduce the amount of time it takes to manipulateconnectors and then electrically connect the multiple electricalcomponents of a mirror to each other and to the vehicle electricalsystem.

[0004] Another problem caused by multiple components in a mirror is thatthe mirror becomes thicker in order to make room for the wiring andconnectors and also heavier due to the connectors, wires, and relatedsupport structure. Modern vehicles place a high emphasis on low weightand small size, especially for non-visible components. Weight, even insmall amounts, is an issue in electrochromic mirror subassembliesbecause these mirrors use a pair of glass elements with anelectrochromic layer therebetween. They also require the supportingcircuitry and hardware. Glass has a relatively high specific gravity,and since electrochromic mirror subassemblies require a pair of glasselements, these mirror subassemblies tend to be heavier thannon-electrochromic mirrors. In opposition to the issue of reducingweight by reducing glass thickness, glass elements must be thick enoughto prevent distortion of reflected images, since this is related to avehicle driver's ability to see around and safely drive a vehicle. Mostexisting mirror glass elements in EC mirror subassemblies are about2.2-mm in thickness or greater. Vehicle manufacturers have hesitatedgoing below this thickness because the glass elements will bend tooeasily, resulting in distortion of the reflected images. Further, a wayis needed to support the glass elements in a non-stressed manner,especially during wide temperature fluctuations and other stress-risingincidents that occur in the environment of a vehicle in service.

[0005] Further, it is preferable that various functions and features bewell integrated into the components of a mirror assembly to minimize thetotal number of parts and pieces. At the same time, it is oftendesirable to maintain reparability so that expensive components do nothave to be scrapped and thrown away when a defect occurs in othercomponents during the last few steps of a manufacturing process for themirror. There is tension between the concept of “integrated features andcomponents” and “reparability” when trying to optimize a mirror formanufacture. For example, “well integrated features and components” tendto require less electrical connectors and less manual assembly (i.e.since the components are integrated into the mirror), and initially costless as a result. However, sometimes it is desirable to add electricalconnectors so that defective components can be removed and replaced andso that scrap can be better controlled and/or so that assemblyefficiency can be improved. Recently, some manufacturers are consideringplacing a turn signal in an exterior vehicle mirror. This can causeseveral difficulties and complications in a mirror. For example, thelight-generating turn signal device adds weight and takes up space, suchthat the resulting assembly is potentially heavier and larger thanmirror assemblies not having this feature. Further, the turn signaldevice requires additional wiring within the mirror assembly, which cancause assembly concerns related to electrical connections andpositioning of connectors, as discussed above. Further, a defective turnsignal device non-removably attached to an electrochromic mirrorsubassembly can result in scrapping out and throwing away a “good”electrochromic mirror subassembly, which is a relatively expensiveportion of the overall assembly at that same point in time. At the sametime, it is desirable to securely attach the turn signal device to themirror assembly so that it does not come loose while in service. Onereason is because, if the turn signal device came loose in an exteriormirror assembly, dirt and light-blocking matter would soon cover theturn signal device, rendering it ineffective. Also, it could rattle andcause other problems.

[0006] It is desirable to improve assembly of the electrochromic mirrorsubassembly to the angular adjustment mechanism (often called a “powerpack”). Historically, the power pack includes an electrically-poweredangularly-adjustable mount, and the electrochromic mirror subassemblyincludes a carrier with a connector having resilient fingers shaped tosnappingly engage the adjustable mount. However, as the resilientfingers are flexed to engage and then do engage the adjustable mount,the glass-supporting area around the fingers is distorted. This can be aproblem since, if the glass is less than about 2.2-mm thick and thecarrier thickness is also minimized for reduced weight, the distortionof the glass-supporting area can read through to the glass, causingnoticeable and objectionable distortions in the reflected images.Distortion of the glass-supporting area can be reduced by making thefingers flimsier and not as stiff, however this would result in areduced retention force and less reliable connection of theelectrochromic mirror subassembly to the power pack. Distortion of theglass-supporting area can also potentially be reduced by placement ofperpendicular reinforcement webs on the carrier. This, however, addsweight and takes up considerable space if the reinforcement webs aremade large enough to do an adequate job. Further, testing has shown thatit is not a solution to this problem to merely add a few randomreinforcement webs, since very minor bending in a directionperpendicular to the glass elements of the mirror subassembly in anylocalized area can result in objectionable glass distortions, especiallywith glass elements at or under 1.6-mm thickness. It is important thatthe insertion force for attaching the carrier to the adjustable mountnot be too high of force, that it not be an inconsistent force, and yetthat the retention force not permit looseness, sloppiness, poor andinconsistent retention forces.

[0007] In addition to the above, it is desirable to design a carrier forthe EC mirror subassembly that can be molded with molding dies that arenot complicated and that do not include a plurality of movable pulls andslides that are difficult to maintain. Pulls and slides in molding diesare well known, and are often used to mold parts. However, pulls andslides are expensive to build into a die and to maintain, and can resultin increased scrap. Further, it is desirable to provide a carrier thatprovides ease and reliability of assembly, with few parts and pieces,especially having few small parts and pieces such as screws and separatefasteners that must be manipulated and/or connected without stripping.

[0008] Accordingly, a mirror assembly is desired solving theaforementioned problems and having the aforementioned advantages.

BRIEF SUMMARY OF THE INVENTION

[0009] In one aspect of the present invention, a mirror assemblyincludes an electrochromic mirror including a first connector operablyconnected to the electrochromic mirror, and an electrically-operatedsecond component associated with the electrochromic mirror that includesa second connector operably connected to the electrically-operatedsecond component. A primary wire bundle extends from and is configuredto communicate power to the electrochromic mirror and to theelectrically-operated second component, the primary wire bundleincluding a main connector. The first connector engages and iselectrically connected to the main connector, and the second connectorengages and is electrically connected to one of the main connector andthe first connector. By this arrangement, the primary wire bundle isconfigured to communicate power to the electrochromic mirror and to thesecond component in a manner minimizing the number of electricalconnections and connectors necessary during assembly to a mirrorhousing.

[0010] In another aspect of the present invention, a rearview mirrorassembly for a vehicle includes a housing, and a mirror subassemblypositioned in the housing and including a panel-shaped carrier. Firstand second electrically-operated components are associated with themirror subassembly and include first and second connectors,respectively. A primary wire bundle extends from and is configured tocommunicate power to the first and second components, the primary wirebundle including a main connector. The first and second connectorsengage and are electrically directly connected to the main connector. Bythis arrangement, the primary wire bundle and the first and secondconnectors are configured to communicate power to the first and secondcomponents in a manner minimizing the number of electrical connectionsnecessary during assembly to a vehicle.

[0011] In another aspect of the present invention, a rearview mirrorassembly for a vehicle includes a mirror subassembly, and a heaterpositioned relative to the mirror subassembly for heating the mirrorsubassembly. The heater includes a first connector on one side of theheater and a second connector on another side of the heater with anelectrical conductor extending through and across the heater andconnecting the first and second connectors. By this arrangement,electrical energy can be communicated by the electrical conductor todifferent sides of the heater for operating an electrically operatedcomponent associated with the mirror subassembly.

[0012] In a narrower form, the mirror assembly includes anelectrically-operated second component associated with the mirrorsubassembly, the second component including a third connector engagingthe second connector for electrifying the second component.

[0013] In still another narrower form, the rearview mirror assemblyincludes a primary wire bundle extending from and configured tocommunicate power to the heater and the second component, the primarywire bundle including a main connector engaging and electricallyconnected to the first connector, whereby the primary wire bundle isconfigured to communicate power to the first and second components in amanner optimizing the positions of electrical connections necessaryduring assembly to a vehicle.

[0014] In another aspect of the present invention, a rearview mirrorassembly for a vehicle includes a mirror subassembly, and a heaterpositioned relative to the mirror subassembly for heating the mirrorsubassembly. The heater is multi-layered and includes a polymeric layerof light-transmitting material and includes another layer of opaquematerial with at least one aperture therein for letting light passthrough to the light-transmitting material. At least a portion of thelight-transmitting material covers the aperture and is configured todiffuse light passing through the portion. A light source directs lightat the portion, with the portion diffusing the light so that the lightpassing therethrough is uniformly distributed.

[0015] In another aspect of the present invention, a mirror includes anelectrochromic mirror subassembly including a panel-shaped carrier withflanges defining a pocket, and a printed circuit board positioned in thepocket. A releasable retainer releasably secures the printed circuitboard in the pocket.

[0016] In another aspect of the present invention, an exterior rearviewmirror includes a mirror subassembly including a panel-shaped carrier,and a printed circuit board attached to the panel-shaped carrier. Theprinted circuit board includes light-generating devices positioned in avisible location on the mirror subassembly to generate a visible turnsignal and includes at least a portion of a circuit for controlling thelight-generating devices. A retainer secures the printed circuit boardto the mirror subassembly characteristically without using a separatehousing for the printed circuit board.

[0017] In another aspect of the present invention, a mirror assemblyincludes a housing, and an adjustment device attached to the housing.The adjustment device includes an angularly adjustable mount. Anelectrochromic mirror subassembly includes front and rear glass elementsand an electrochromic layer adapted to provide controlled darkening ofreflected images, and further includes a panel-shaped carrier with afront surface shaped to uniformly support the rear glass element. Thepanel-shaped carrier includes a plurality of resilient retainersarranged in a circle. The resilient retainers extend rearwardly from thepanel-shaped carrier and engage the adjustable mount. The panel-shapedcarrier further includes a continuous hoop-shaped wall extending aroundand spaced radially from the plurality of resilient retainers. Thehoop-shaped wall extends from the rear surface and supports an areaaround and proximate a base of the plurality of resilient retainers sothat significant deflection of the panel-shaped carrier in the area ofthe resilient retainers is prevented even when the resilient retainersare stressed or have been stressed.

[0018] In still another aspect of the present invention, a mirrorassembly includes a housing and an adjustment device attached to thehousing. The adjustment device includes an angularly adjustable mount.An electrochromic mirror subassembly includes front and rear glasselements and an electrochromic layer adapted to provide controlleddarkening of reflected images, and further including a panel-shapedcarrier with a front surface shaped to uniformly support the rear glasselement. The panel-shaped carrier includes a plurality of resilientretainers arranged in a circle and extending rearwardly from thepanel-shaped carrier and engaging the adjustable mount. The retainersand adjustable mount are configured to positively engage for secureretention, but are also configured to provide an insertion attachmentforce of less than 50 pounds force (about 220 N) during assembly of thepanel-shaped carrier to the adjustment device.

[0019] In yet another aspect of the present invention, an exteriormirror assembly includes a housing with an arm adapting the housing forattachment to a vehicle in a position outside of the vehicle. Anadjustment device is attached to the housing and includes an angularlyadjustable mount. A mirror subassembly includes an electrochromic mirrorand a carrier for the electrochromic mirror. The carrier includes apanel-like surface supporting the electrochromic mirror and includesretainers engaging the adjustable mount. The carrier includes aplurality of apertures inboard of a perimeter of the carrier butoutboard of a perimeter of the electrochromic mirror, and further, themirror subassembly includes a bezel with a plurality of resilient hooksthat extend past the perimeter of the electrochromic mirror and into theplurality of apertures.

[0020] It is an object of the present invention to provide a vehiclemirror that is particularly suited for use as a vehicle mirror, wherethe mirror includes numerous electrical components that must be poweredand also controlled, including such components and features aselectrochromic (EC) layers, heaters, turn signals, power packs forpowered angular adjustment of the mirror subassembly, sensors, readoutsand displays, and turn signals. It is an object of the present inventionto provide electrical connector arrangements that facilitate connectionof multiple connectors with minimized manual labor, minimized expensivecomponents, minimized space problems, and optimized locations.

[0021] It is an object of the present invention to integrate componentsto reduce redundant structure, to reduce overall thickness of theassembly, and to eliminate parts.

[0022] It is an object of the present invention to incorporate structurefor the housing of the urn signal device into other structure within themirror subassembly, as a way of reducing expense and assembly labor,saving space, saving material and reducing weight of the mirrorassembly.

[0023] It is an object of the present invention to releasably hold thecircuit board in the mirror subassembly, and hence provide a circuitboard and electrical component arrangement that is serviceable andreparable in the field and also serviceable and reparable at the time ofassembling the mirror assembly. In particular, it is an object toprovide a mirror assembly process that reduces scrap and cost of scrapby allowing serviceability as late in the mirror assembly process aspossible, and by attaching non-removable components as late as possiblein the assembly process.

[0024] It is an object of the present invention to provide anelectrochromic mirror subassembly that utilizes glass elements having arelatively thin thickness dimension, such as a thickness of 1.6-mm or aslow as 1.1-mm or lower, and to support these glass elements in astress-free and forgiving manner that minimizes distortion. Inparticular, an object is to provide a carrier that supports the glasselements with minimal stress, yet that allows snap-assembly of a mirrorsubassembly to a power pack, and that allows snap-assembly of a bezel tothe mirror subassembly.

[0025] It is an object of the present invention to provide a minimizedinsertion force when attaching a mirror carrier to a power pack. Inparticular, it is desired that the insertion force not be unacceptablyhigh, such as below 50 pounds force of insertion, but that it be aconsistent force, that it be well-distributed and not be concentrated,that looseness and sloppiness be prevented, that the retention forces benon-distorting to the mirror glass elements, and that stresses resultingfrom environmental conditions such as temperature fluctuations notunacceptably bend glass elements and read through onto reflected images.

[0026] It is an object of the present invention to provide componentsthat can be molded with molding dies that are relatively low-cost tobuild and maintain, such as by providing parts and components that canbe molded using dies without movable pulls and without movable slides,which die pulls and slides are expensive to build into dies and tomaintain.

[0027] It is an object of the present invention to construct a mirrorassembly that includes components that are easy to build and assemble,and that can be assembled reliably and efficiently with low cost.

[0028] It is an object of the present invention to provide a mirrorassembly that includes relatively few parts and pieces, especially smallparts and pieces that must be manipulated and connected during assembly.It is desired to include in the mirror assembly fewer loose parts andpieces, especially parts and pieces that can be mislocated and that canget in the way and/or rattle and/or that must be accurately positionedduring assembly.

[0029] These and other aspects, objects, and features of the presentinvention will be understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030]FIG. 1 is a perspective view of an exterior mirror assemblyembodying the present invention;

[0031]FIG. 2 is an enlarged schematic view of an angular adjustmentmechanism (i.e. an electrical “power pack”) attached to anelectrochromic mirror subassembly, with the flexible fingers of themirror carrier being bent in a manner causing distortion of reflectedimages;

[0032]FIG. 2A is a cross section similar to FIG. 2, but showing adeformation of the glass elements in a mirror subassembly caused bybending of the carrier, leading to distortion of a reflected image;

[0033]FIG. 3 is a rear view of the mirror subassembly, which shows therear surface of the carrier and also the wiring and electrical connectorarrangement;

[0034]FIGS. 4 and 5 are cross-sectional views taken along the linesIV-IV and V-V in FIG. 3;

[0035]FIG. 6 is an enlarged view of the circuit-board-holding pocket ofthe carrier, which is an enlarged view of the right end of FIG. 4;

[0036]FIG. 7 is an enlarged cross-sectional view taken along the lineVII-VII in FIG. 3;

[0037]FIGS. 8 and 9 are cross-sectional views of the carrier andintegrally molded door retainer, similar to FIG. 7 but showing only thecarrier (i.e. the mirror subassembly and circuit board are not shown),FIG. 8 showing the door retainer in an open position and FIG. 9 showingthe door retainer in a closed position (compare to FIG. 7);

[0038]FIG. 10 is a rear view of a modified mirror subassembly, includinga three-into-one electrical connector arrangement;

[0039]FIG. 11 is a fragmentary view of the three-into-one electricalconnector of FIG. 10;

[0040]FIG. 12 is a rear view of a modified mirror subassembly, includingan upstream two-into-one electrical connector and then a downstreamtwo-into-one electrical connector;

[0041]FIG. 13 is a rear view of another modified mirror subassembly,including a two-into-one electrical connector and also a “piggyback”electrical connector that plugs into or “piggybacks” onto a back of oneof the first electrical connectors;

[0042]FIG. 14 is a fragmentary plan view of a heater including alight-blocking layer with apertures for letting light pass through, andincluding a light-passing layer treated to diffuse light passingtherethrough; and

[0043]FIG. 15 is a cross-sectional view taken along line XV-XV in FIG.14.

DETAILED DESCRIPTION

[0044] The illustrated mirror assembly 20 (FIG. 1) includes a housing21, an angular electrically-powered adjustment mechanism 22 (called a“power pack” herein) (FIG. 2) supported in and attached to a wall 21 inthe housing 21, and main wiring bundle 23 (FIG. 1) for powering andcontrolling the power pack 22 and the other components in the mirrorassembly 20. An electrochromic mirror subassembly 24 (FIG. 2) includes acarrier 36 snappingly attached to a multi-angularly-adjustable plate 48on the power pack 22 in a manner that minimizes stress on the glasselements of the mirror subassembly 24, as described below. The presentmirror assembly 20 is designed to prevent the problem illustrated inFIG. 2A, where resilient fingers on the carrier are stressed and havecaused a deformation on the glass elements of the mirror subassembly,resulting in unacceptable distortion of reflected images, as representedby non-parallel reflected light beams 19. (Compare with FIG. 2, wherethree light beams 17 representing an image are reflected as anundistorted image represented by parallel light beams 18.) The mirrorsubassembly 24 (FIG. 2) further includes a layer of electrochromicmaterial 25 and a heater 26, and also an integrally held turn signaldevice 27 (FIG. 3), each of which requires connection to a powering andcontrol device on the vehicle, as described below.

[0045] The components 25, 26, and 27 include individual connectors 25A,26A, and 27A (FIG. 3) that each plug into a multi-prong,multi-receptacle main connector 28 or secondary connector 28A on thebundle of wires 23. Alternatively, it is contemplated that a pair of theconnectors could piggyback into each other (see FIG. 13), with thebottom connector being plugged into the connector 28. Still anotheralternative is to use an “extension cord-type” arrangement where twotwo-prong connectors plug into a single four-prong connector and thendownstream the extension cord's other connector plugs into the mainconnector (see FIG. 12). This arrangement can help provide flexibilityfor assembly, particularly when different options are used for themirror assembly, the signal device, and the EC mirror subassembly, butalso can help with repair and with control over the type, cost, andnumber of connectors. By this arrangement, commercially available“standard” connectors can be used instead of higher-cost “specialty”connectors. Another alternative arrangement includes a heater thatincorporates an internal wire with end connectors for communicatingpower to opposite sides of the heater (FIG. 12). Optionally, the heatercan also include sections of light-transmitting/diffusing material 34(see FIGS. 14-15) for diffusing light 35 passing from the turn signaldevice 27 through the diffusing material 34.

[0046] The mirror subassembly 24 includes a panel-shaped carrier 36(FIGS. 6-9) constructed to securely but releasably hold a circuit board38 of the turn-signal device 27 and also constructed with a continuoushoop flange 44 for rigidity. More specifically, the mirror subassembly24 includes flanges 72 and 72A forming a pocket 37. A printed circuitboard 38 with light-generating devices 39 (such as LEDs) (FIG. 15) forgenerating a pattern of light for the turn signal fits into the pocket37. A door retainer 40 (FIGS. 6-9) is integrally molded with the carrier36, and includes an integral hinge 41 and snap-attach retainers 42 thatreleasably secure the door retainer 40 in a closed position for securingthe printed circuit board 38 in the pocket 37. The carrier 36 alsoincludes a ring-shaped array of resilient fingers or retainers 43configured to snappingly engage a mounting plate on the power pack 22. Acontinuous hoop flange 44 (FIG. 3) of carrier 36 extends around thefingers 43 to prevent unacceptable distortion of the carrier 36 when thefingers 43 are attached to the power pack 22.

[0047] Exterior mirror housings such as housing 21 (FIG. 1) and alsoadjustable power packs such as power pack 22 (FIG. 2) are generally wellknown in the art, such that the present housing 21 and power pack 22need not be described in great detail for an understanding of thepresent invention by a person skilled in the art of designing vehiclemirrors. It is sufficient to describe the housing 21 as including afront opening 46 in which the mirror subassembly 24 is adjustably heldfor angular adjustment by the power pack 22. The power pack 22 includesDC motors 47 for angularly adjusting an adjustable plate or mount 48 inorthogonal X-Y angular directions. The resilient fingers 43 on thecarrier 36 snappingly engage the adjustable plate 48 in a manner thatfacilitates assembly via a low and consistent insertion force, yetpositively retain the carrier 36 to the power pack 22 with aconsistently high retention force, as described below. The housing 21further includes a rigid structural arm 49 with attachment bolts 49′shaped for secure attachment to a vehicle body or door (not specificallyshown).

[0048] The carrier 36 (FIGS. 3-4) includes a panel-like body section 50shaped to fit inside the opening 46 of housing 21 and to support themirror subassembly 24. The mirror subassembly 24 (FIG. 6) includes afront glass element 51 having a thickness of about 1.6-mm or that ismore preferably about 1.1-mm or less, and a rear glass element 52 havinga thickness of about 2.2-mm to 1.1-mm or that is more preferably about1.6-mm. An electrochromic (EC) substance 53 is located between the glasselements 51 and 52. A reflector layer 54 is applied to a rear of therear glass element 52 (i.e. a fourth surface reflector) (as illustrated)or to a front of the rear glass element 52 (i.e. a third surfacereflector). It is contemplated that the EC substance can be a solutionphase material, a solid phase material, a gel material, or a hybridthereof or any other material that is darkenable in a controlled manner.An electrochromic mirror subassembly 24 of interest having low-thicknessglass elements is described in detail in U.S. Pat. No. 6,195,194, whichpatent is incorporated in its entirety herein by reference.

[0049] The heater 26 includes a foam layer 55 and a plastic layer 56(e.g. Mylar or stiff plastic) with conductive tracings 57 thereon thatform the heater element. In the illustrated arrangement, the plasticlayer 56 is adhered to the reflector layer 54, and the foam layer 55 isadhered to the plastic layer 56 but not adhered to the carrier 36.Notably, the plastic and foam layers 56 and 55 could be reversed, and/orthe adhesive layer could be on the foam layer instead of the plasticlayer. The illustrated lack of adhesion between the plastic layer 56 andthe carrier 36 is a change from prior art that helps reduce stress onthe glass elements 51 and 52. For example, such stress will occur due tonon-uniform thermal expansion, such as may occur during the day and/oroccur when the heater is first energized and is heating. This lack ofadhesion helps to reduce unacceptable distortion of the glass elements51 and 52 by permitting some slippage between the heater and the mirrorsubassembly 24.

[0050] The carrier 36 (FIG. 6) includes a perimeter section with aU-shaped edge flange 58 having an aperture 59. A bezel 60 includes aJ-shaped body 61 that extends around a perimeter of the mirrorsubassembly 24, with a short end of the J-shaped body 61 engaging anarea on the front glass 51 just inside of a perimeter of the front glass51, and with a long end of the J-shaped body 61 extending past the glasselements 51 and 52 into a groove formed by the U-shaped edge flange 58.The long end of the J-shaped body 61 is resilient and flexible, andincludes a plurality of hooks 63 shaped to snap into the apertures 59.Due to the shape of the mating U-shaped edge flange 58 and the bezel 60,the bezel 60 securely and reliably fits into the groove of the U-shapededge flange 58 and snaps into the apertures 59. In particular, the shapeof the U-shaped edge flange 58 permits an assembler to flex the U-shapededge flange 58 forwardly, and permits an assembler to flex the short endof the J-shaped body 62 rearwardly, thus helping to assemble the bezel60 onto the edge flange 58 without “overflexing” and non-uniformlystressing and/or deforming the mirror subassembly 24 or the bezel 60 orthe carrier 36. Also, the arrangement helps prevent permanent“overflexing” or assembly-induced stress which would result inunacceptably/non-uniformly stressing or locally bending an edge of themirror subassembly 24. The section 64 of foam layer 55 along theperimeter of the heater 26 forms a compressed sandwich with the mirrorsubassembly 24, the bezel 60 and the carrier 36, with the foam section64 being compressed to about half its uncompressed thickness. Notably,the bezel 60 transmits compressive forces directly through the glasselements 51 and 52 of the mirror subassembly 24, thus substantiallyeliminating undesired torsional and bending stresses.

[0051] The carrier 36 also includes the hoop flange 44, which stabilizesand rigidifies the panel-like body section 50 of the carrier 36 aroundthe power-pack-attachment section (i.e. around the resilient snap-attachfingers 43). The hoop flange 44 is continuous, such that it inherentlyhas the strength and stress-distributing properties of a hoop. Further,the hoop flange 44 has a height of about 10-mm and a thickness at itstop edge of about 0.8-mm. This ratio of dimensions is an optimalcompromise permitting moldability (with minimal draft angle), whileproviding the strength and structure to provide support to resistresonant frequencies that can be problematic to an exterior mirror 20 inthe field when a car is in service. Reinforcement ribs 66 (FIG. 3)extend radially from the outer edge surface of the hoop flange 44 forstabilizing the hoop flange 44 on a rear of the panel-like body section50. The ribs 66 are located as needed. Some of the ribs 66 are extendedto provide support locations for electrical connectors, such as rib 66Adescribed below.

[0052] A hole 67 is located in the panel-like body section 50 in amiddle area of the attachment section (i.e. in a middle area of the ringof fingers 43). The hole 67 prevents “oil canning”, which is a conditionthat sometimes occurs on flat molded walls that are surrounded by rigidperimeter structure. “Oil canning” is the condition where flat materialflexes between “in” and “out” bowed conditions. The presence of the hole67 is consistent with the present structure, which emphasizes lettingthe glass element 51 and 52 of the mirror subassembly 24 float to anunstressed state, rather than attempting to continuously support theglass elements 50 and 51 in all locations across its rear surface. AU-shaped open area 69 is cut away from a root or base of the fingers 43to provide additional flexure of these fingers 43. Specifically, theU-shaped open area 69 is cut into the panel-like body section 50 toallow the fingers 43 to flex in a direction perpendicular to the fingers43. The U-shaped open area 69 causes the fingers 43 to flex open moreeasily, and lets them flex without disturbing and over-stressing thepanel-like body section 50. At the same time, an installer can pressdirectly on a back side of the fingers 43 to assure that the fingers 43are all securely snapped onto the plate mount 48 on the power pack 22.The fingers 43 (FIG. 6) include a hook-shaped end having an angledsurface 70 and they extend about 14-mm to 15-mm. The angled surface 70is polished and/or otherwise treated to reduce the friction ofinsertion. By polishing the angled surface 70, insertion forces of under50 pounds force (222 Newtons) have been achieved, which is surprisinglyand unexpectedly low for assembling a mirror subassembly 24 onto a powerpack 22. Many previous attempts have been made in the art to reduceinsertion forces, while maintaining a sure and consistently tight fit.The present arrangement of polished hook surfaces and flexible fingers43, in combination with the compressed foam of the heater 26, isbelieved to be novel and non-obvious to a person of ordinary skill inthis art, based on the effort that has gone into coming to the presentsolution to the problem.

[0053] The carrier 36 is a molded component having flanges 72 and 72A(FIG. 6) on all sides forming a well-defined boomerang-shaped pocket 37.(See FIG. 14.) A circuit board 38 (FIG. 6) is crescent-shaped orboomerang-shaped to fit mateably into the pocket 37, with edges of thecircuit board 38 being captured by the various flanges 72 and 72A. Aresilient angled biasing flange 73 (FIG. 7) on the carrier 36 is shapedto engage a side edge of the circuit board 38 to assure non-rattlingretention of the circuit board 38. The door-shaped retainer 40 is moldedas shown in FIG. 8, but is bendable about integral living hinge 41 intosnapping engagement with the integrally-molded retainers 42. Whenclosed, the door-shaped retainer 40 includes an edge opposite the livinghinge 41 that engages two hook-shaped retainers 42. However, it is to beunderstood that retainers (42) can be included to engage top and bottomedges of the retainer 40 as well. When closed, the door-shaped retainer40 engages the resilient biasing flange 73 in a manner that compressesthe retainer 40 against the blind surfaces on the hook retainers 42,thus assuring non-rattling securement of the door-shaped retainer 40.Notably, the living hinge 41 extends only about half a length of thedoor 40, such that wires 27A′ can be slid sideways into the hinge areaand routed into the pocket 37 without interference from the door 40 orhinge 41 or flanges 72 and 72A. The circuit board 38 includes thelight-generating devices 39 and circuits necessary for controlling thelight-generating devices 39 to generate an arrow-shaped turn signal. Itis noted that turn-signals have previously been put on external vehiclerearview mirrors (for example, see U.S. Pat. No.6,166,848), but it isbelieved that no one has eliminated the separate turn signal housingshown in U.S. Pat. No. 6,166,848. The present apparatus incorporates thestructure for holding the turn signal circuit board and LEDs into thecarrier of the mirror subassembly itself. Notably, the illustratedcarrier 36 is designed so that it can be molded by dies that do not haveany die pulls, slides, cams, or moving components for making blindsurfaces. This lowers cost, reduces maintenance, reduces capitalinvestment, reduces scrap, and leads to an improved and more reliablemanufacturing process and better parts.

[0054] The present structure further incorporates the turn signal device27 into the mirror subassembly structure by using the plastic layer 56(FIG. 15) of Mylar in the heater 26 as a diffuser for thelight-generating devices 39 on the turn-signal device 27. Specifically,one or more apertures 74 are cut into the foam layer 55 of the heater26. The apertures 74 can be cut entirely through the foam if the lightgenerated by the turn signal device 27 is sufficiently dispersed toprovide a uniformly lit turn signal. However, the illustrated heater 26has a clear plastic layer 56 that extends across the pattern ofapertures 74. The plastic layer 56 is Mylar or similar clear material,and at least the area of sections 34 at the apertures 74 is roughened orotherwise treated to form a light-spreading/diffusing surface 34 overthe apertures 74. This surface causes the light 35 from LEDs 39 todiffuse into a more uniform distribution of light. Bars 39′ (FIG. 15) inthe windows on the EC material 53 and the relationship of componentscauses the emitted light 35′ to be visible. By this method, the need forseparate window/light diffusers on the light-generating devices 39 ofthe turn signal device 27 are eliminated. However, it is conceivablethat the pattern of apertures 74 can be cut completely through theheater 26, and that a separate light diffusing panel(s) could be usedinstead of the above-described integrated light diffuser that isintegrated into the heater 26.

[0055] The arrangement of connectors for interconnecting theelectrically powered and controlled components of the present mirrorassembly 20 is very important, since connectors take up space,particularly if not well-arranged, since each additional connector addscost, and since they require manual labor to orient and snap together.Further, each additional connector is another opportunity formisconnection, and/or for an electrical short or dead connection.Connectors and wires also add weight and thickness to a mirror assembly.Four connector arrangements are described below, each solving one ormore of the above problems and offering one or more of the aboveadvantages.

[0056] Mirror assembly 20 (FIG. 3) includes the connector 26A, whichcomprises two protruding conductor leads 76 and 77 connected to theheating traces in the heater 26. The main wiring bundle 23 includes afirst connector 28A for operably engaging leads 76 and 77. The mainwiring bundle 23 further includes a second connector 28 that snapengages into or that is incorporated into a holder 81. Holder 81 issnap-attached into an aperture in reinforcement rib 66A. The connectors25A and 27A are configured to snap side-by-side into the holder 81 andelectrically connect to different conductors in the second connector 28on the main wiring bundle 23. It is contemplated that the holder 81 canbe incorporated into the second connector 28 or into one of theconnectors 25A and 27A, if desired. By plugging the two connectors 25Aand 27A side-by-side into the single connector 28, the total number ofconnectors is reduced. Also, the orientation and snap engagement of theconnectors 25A and 27A into connector 28 is easier since there is onelocation, and the first installed connector helps align and orient thesecond connector for installation. Also, the connectors 25A, 27A and 28are located close to connector 28A and leads 76 and 77, which alsofacilitates an efficient assembly, since an assembler does not need towaste time “searching for” the connectors.

[0057] The mirror assembly 20B (FIGS. 10-11) includes wires 83B and aheater connector 26B that replace the heater leads 76 and 77. The mainwiring bundle 23B includes a connector 28B having six prong conductorstherein. Main wiring bundle connector 28B snaps into or is incorporatedinto the holder 81B, which is retained by rib 66B. The EC connector 25B,the heater connector 26B, and the turn signal device connector 27B eachplug side-by-side-by-side into the connector 28B of the main wiringbundle 23B. As noted above, the side-by-side-by-side relationship of theconnectors creates an arrangement that is more efficient to assemble,since all connectors are close together and further since previouslyinstalled connectors guide the later-installed connectors. As arranged,the wires of the connectors 25B, 26B and 27B do not overlap, thusleading to a flatter and well-arranged wiring pattern. Preferably, theconnectors 25B, 26B, and 27B have different shapes so that they are notinterchangeable and cannot be mis-assembled.

[0058] The mirror assembly 20C (FIG. 12) includes conductors 83C thatare integrated into the heater 26C as part of the heater conductortracings. The conductors 83C are used to connect the turn signal device27C to the main wiring bundle 23C in an “extension cord” typearrangement. The turn signal conductors 83C can extend along anyconvenient path from the left side to the right side of the mirrorsubassembly 24C. The turn signal conductors 83C are shown in FIG. 12 asextending horizontally along an upper edge of the heater 26C forconvenience so that they are easily seen in the drawing and so that theydo not interfere with the heater tracings of the heater 26C. It iscontemplated that the turn signal conductors 83C could act as heatingelements as well, but this is not a preferred mode. Instead, it iscontemplated that they will define a separate circuit extending betweenthe turn signal device 27C and the main wires 23C.

[0059] The integrated turn signal conductors 83C can be electricallyinterconnected to the main connector 28C by various means. Theillustrated turn signal conductors 83C include protruding paired ends84C and 85C that are engaged by “L” connectors 86C and 87C,respectively. The turn signal device 27C is held to the carrier by doorretainer 40C, and includes wires 90C connected to connector 86C.Connector 87C engages the downstream protruding paired ends 85C for theturn signal device 27C and further engages the protruding paired ends26C′ extending from heating tracings 26C″. Wires 93C electricallyconnect the four conductors of the connector 87C to the second connector94C which in turn is connected to the main connector 28C. The connector25C connects the electrochromic material of the EC mirror to the mainconnector 28C. Wires 23C extend from the main connector 28C and areconnected to the vehicle electrical system. Mirror 20D (FIG. 13) issimilar to the mirror assembly 20B (FIG. 10), except the connector 27Dfrom the turn signal device 27D′ connects into a rear of the connector25D in a “piggyback” style arrangement, and the connector 25D (which isfour prong) plugs into the main connector 28D adjacent the “EC”connector 26D. More specifically, the connector 25D has two wires fromthe EC mirror subassembly hard wired into the connector 25D, and furtherhas four output prongs for connection to main connector 28D. Connector26D attaches to the main connector 28D beside connector 25D. Wires 23Dextend from connector 28D for connection to the vehicle electricalsystem.

[0060] It is to be understood that variations and modifications can bemade on the aforementioned structure without departing from the conceptsof the present invention, and further it is to be understood that suchconcepts are intended to be covered by the following claims unless theseclaims by their language expressly state otherwise.

1. A mirror assembly comprising: an electrochromic mirror including afirst connector operably connected to the electrochromic mirror; anelectrically-operated second component associated with theelectrochromic mirror and that includes a second connector operablyconnected to the electrically-operated second component; and primarywire bundle extending from and configured to communicate power to theelectrochromic mirror and to the electrically-operated second component,the primary wire bundle including a main connector, the first connectorengaging and electrically connected to the main connector, the secondconnector engaging and electrically connected to one of the mainconnector and the first connector, whereby the primary wire bundle isconfigured to communicate power to the electrochromic mirror and to thesecond component in a manner minimizing the number of electricalconnections and connectors necessary during assembly to a mirrorhousing.